Wireless Charging Device

This application claims the benefit of U.S. provisional application Ser. No. 63/631,481, filed Apr. 9, 2024, the subject matter of which is incorporated herein by reference, and claims the benefit of Taiwan application Serial No. 113131438, filed on Aug. 21, 2024, the subject matter of which is incorporated herein by reference.

The invention relates in general to a wireless charging device

Due to environmental protection, consumers' demand for electric vehicles is increasing day by day. Therefore, the electric vehicle market has also begun to have demand for wireless charging. When the electric vehicle is located above the wireless charging device, the wireless charging device may charge the electric vehicle. However, if the electric vehicle accidentally rolls over the wireless charging device, the wireless charging device may be easily damaged. Therefore, proposing a wireless charging device capable of improving the aforementioned problems is one of the goals of those in this technical field.

According to an embodiment of the present invention, a wireless charging device is provided. The wireless charging device includes a first cover, a second cover, a foreign object detection component and a coil carrier tray. The foreign object detection component is disposed between the first cover and the second cover and has a through hole. The coil carrier tray is disposed between the first cover and the second cover and includes a protrusion, wherein the protrusion passes through the through hole and abuts against the first cover.

According to another embodiment of the present invention, a wireless charging device is provided. The wireless charging device includes a first cover, a second cover, a foreign object detection component, a coil carrier tray and an energy induction tray. The foreign object detection component is disposed between the first cover and the second cover. The coil carrier tray is disposed between the first cover and the second cover. The energy induction tray is disposed between the first cover and the second cover. The first cover abuts against the coil carrier tray, the coil carrier tray abuts against the energy induction tray, and the energy induction tray abuts against the second cover.

The above and other aspects of the invention will become better understood with regard to the following detailed description of the preferred but non-limiting embodiment(s). The following description is made with reference to the accompanying drawings.

Referring to,illustrates a schematic diagram of a wireless charging deviceaccording to an embodiment of the present invention,illustrates a schematic diagram of a top view of the wireless charging devicein(not illustrated),illustrates a schematic diagram of the wireless charging deviceindisposed on a carrier,illustrate schematic diagrams of exploded views (not illustrates the energy induction component) of the wireless charging deviceinfrom different angles,illustrates a schematic diagram of a cross-sectional view of the wireless charging deviceinalong a directionA-A′,illustrates a schematic diagram of a cross-sectional view of the wireless charging deviceinalong a directionB-B′, andillustrates a schematic diagram of a cross-sectional view of the wireless charging deviceinalong a directionC-C′.

As illustrated in, the wireless charging devicemay be disposed on the carrier, and configured to charge the electronic device located on the wireless charging device. The carrieris, for example, a ground, a floor, or any other carrier that may carry the wireless charging device. The electronic device is, for example, an electric vehicle with at least one wheel, such as an electric motorcycle, an electric car, an electric bicycle, etc.

As illustrated in, the wireless charging deviceincludes at least a first fixing componentA, at least a second fixing componentB, at least a third fixing componentC, a first cover (or a top cover), a second cover (or a bottom case), at least one foreign object detection (FOD) component, a coil carrier tray, a charging coil, an energy induction tray, at least one energy induction component, an insulation component, a sealing component, a pressing plate, a first circuit boardA and a second circuit boardB.

As illustrated in, the foreign object detection componentis disposed between the first coverand the second coverand has at least one through hole. The coil carrier trayis disposed between the first coverand the second coverand includes at least one protrusion, wherein the protrusionpasses through the through holeand abuts against the first cover. As a result, a force F(for example, a vehicle weight) exerted on the first covermay be transferred to the carrierthrough the coil carrier tray.

As illustrated in, the first coverand the coil carrier traymay directly or indirectly abut against each other. In the present embodiment, the first coverand the coil carrier traydirectly abut with each other. The term “directly abut” herein means that two components are directly connected without other component between them, while the term “indirectly contact” means that the two components are connected through other component. The first coverhas a lower surface, and the protrusionhas an end surface. The end surfaceof the protrusionabuts against the lower surfaceof the first coverto transfer the force F. In an embodiment, the protrusionis in surface contact with the first cover, which may reduce the pressure of the force Facting on the surface. In an embodiment, the end surfaceof the protrusionand the lower surfaceof the first coverare, for example, flat surfaces (planes). The first coverincludes at least one abutting post, and each abutting posthas a fixing hole. The second coverincludes at least one abutting post, and each abutting posthas a through hole. The first fixing componentA may pass through the through holeof the abutting postand be fixed to the fixing holeof the abutting postof the first coverto fix a relative position of the first coverand the second cover. In an embodiment, the fixing holeis, for example, a threaded hole, and the first fixing componentA is, for example, a threaded component.

As illustrated in, the second coverincludes a cover bodyand an abutting portion. The cover bodyhas a lower surface, and the abutting portionis connected to the lower surfaceand protrudes relative to the lower surface. The pressing plateand the second covermay directly or indirectly abut against each other. In the present embodiment, the pressing plateand the second coverdirectly abut against each other. The abutting portionhas an end surface, and the end surfaceof the abutting portionmay abut against an upper surfaceof the pressing plate.

As illustrated in, the foreign object detection componentis disposed between the first coverand the coil carrier tray. The foreign object detection componentincludes a carrier plateand at least one foreign object detection coil (FOD coil). The carrier platehas an upper surface, and the foreign object detection coilis disposed on the upper surfaceof the carrier plate. The foreign object detection coilis configured to detect whether there is a foreign object located above the wireless charging device. The carrier platehas the aforementioned through hole, and the foreign object detection coilsurrounds the through holeand does not overlap with the through hole(as illustrated in), and thus it may prevent the protrusionfrom interfering with the foreign object detection coilafter passing through the through hole. In the present embodiment, the number of the foreign object detection componentsis multiple, for example, five. However, the embodiment of the present invention is not limited to this.

As illustrated in, the coil carrier trayis disposed between the foreign object detection componentand the second cover. The coil carrier trayincludes a coil carrier plateand an abutting portion. The coil carrier platehas a lower surface. The abutting portionis disposed on the lower surfaceand protrudes relative to the lower surface. The abutting portionsurrounds at least one groove. The charging coilmay be disposed in the groove. In the present embodiment, the charging coilis entirely located in the groove, and it may prevent the charging coilfrom protruding relative to the end surfaceof the abutment portion, thereby preventing the charging coilfrom interfering with components below the charging coil(for example, the insulation component). Due to the charging coilbeing entirely located within the groove, the force Fmay not be transferred to the charging coil, and it may avoid damaging the charging coil. In addition, the end surfacemay directly or indirectly abut against the upper surfaceof the insulation component.

As illustrated in, the coil carrier trayfurther includes at least one first abutting portionand at least one second abutting portion. The coil carrier platehas an upper surface. The first abutting portionmay be disposed on the upper surfaceand protrude relative to the upper surface. For example, the first abutting portionmay be connected to an edge of the upper surface. The second abutting portionis connected to the first abutting portion. The first abutting portionand at least one second abutting portionseparate at least one groove. The aforementioned protrusionis located in the groove. In addition, the number of the groovesand the number of the foreign object detection componentsare equal. Each foreign object detection componentmay be disposed in the corresponding groove. In the present embodiment, the foreign object detection componentmay be entirely located in the groove. As a result, the force Fis not transferred to the foreign object detection component, and it may avoid damaging to the foreign object detection component.

As illustrated in, the first abutting portionhas an end surface. The end surfaceof the first abutting portionmay directly or indirectly abut against the lower surfaceof the first cover. In the present embodiment, the end surfacedirectly abuts against the lower surface. As illustrated in, the second abutting portionhas an end surface. The end surfaceof the second abutting portionmay directly or indirectly abut against the lower surfaceof the first cover. In the present embodiment, the end surfacedirectly abut against the lower surface

As illustrated in, the energy induction trayis disposed between the first coverand the second cover. The energy induction trayand the coil carrier traymay be engaged with each other. In addition, the energy induction trayand the coil carrier traymay directly or indirectly abut against each other. In the present embodiment, the energy induction trayand the coil carrier trayindirectly abut against each other. For example, the energy induction trayabuts against the coil carrier traythrough the insulation componentto transmit the force F. In another embodiment, the wireless charging devicemay omit the insulation component. As a result, the energy induction trayand the coil carrier traymay directly abut against each other to transmit the force F. In the present embodiment, the energy induction trayis an object containing magnetically conductive material, such as a magnetically conductive disk.

As illustrated in, the energy induction trayincludes an energy induction carrier plate, at least one third abutting portion, and at least one fourth abutting portion. The energy induction carrier platehas an upper surface. The third abutting portionmay be disposed on the upper surfaceand protrude relative to the upper surface. For example, the third abutting portionmay be connected to an edge of the upper surface. The fourth abutting portionmay be disposed on the upper surfaceand protrude relative to the upper surface. The fourth abutting portionis connected to the third abutting portion. The third abutting portionand at least one fourth abutting portionseparate at least one groove. Each energy induction componentmay be disposed in the corresponding groove. In the present embodiment, the energy induction componentmay be entirely disposed in the corresponding groove. As a result, the force Fmay not be transferred to the energy induction component, and it may avoid damaging the energy induction component. In the present embodiment, the energy induction componentis an object containing magnetically conductive material, such as a magnetically conductive sheet.

As illustrated in, the third abutting portionhas an end surface. The end surfaceof the third abutting portionmay directly or indirectly abut against the lower surfaceof the insulation componentto transmit the force F. In addition, the third abutting portionand the insulation componentare in surface contact, and it may reduce the pressure of the force Facting on the surface. In the present embodiment, the end surfaceof the third abutting portionis directly connected to the lower surfaceof the insulation component. The fourth abutting portionhas an end surface. The end surfaceof the fourth abutting portionmay directly or indirectly abut against the lower surfaceof the insulation componentto transmit the force F. In addition, the fourth abutting portionand the insulation componentare in surface contact, and it may reduce the pressure of the force Facting on the surface. In the present embodiment, the end surfaceof the fourth abutting portiondirectly abut against the lower surfaceof the insulation component. In another embodiment, the wireless charging devicemay omit the insulation component. As a result, the end surfaceof the fourth abutting portionof the energy induction traymay directly abut against the end surfaceof the abutting portionof the coil carrier trayto transmit the force F.

As illustrated in, the energy induction trayand the second covermay directly or indirectly abut against each other. In the present embodiment, the energy induction trayand the second coverdirectly abut against each other. The energy induction trayhas a lower surface, and the aforementioned second coverhas an upper surface. The upper surfaceof the second covermay directly or indirectly abut against the lower surfaceof the energy induction trayto transmit the force F. In addition, the second coverand the energy induction trayare in surface contact, and it may reduce the pressure of the force Facting on the surface. In the present embodiment, the upper surfaceof the second coverand the lower surfaceof the energy induction traydirectly abut against each other. In an embodiment, the lower surfacemates with upper surface. For example, the lower surfaceand the upper surfaceare both flat surfaces, but they may also be matching curved surfaces.

As illustrated in, the energy induction componentis, for example, a magnetic core. The magnetic core is made of ferrite, for example. Ferrite is a ceramic material with iron oxide as its main component. Ferrite, for example, is magnetic and may be used to make permanent magnets, transformer cores and other related applications.

As illustrated in, the insulation componentis disposed between the first cover(or the charging coil) and the second cover(or the energy induction tray). The insulation componenthas an upper surfaceand a lower surface. In the present embodiment, the abutting portionof the coil carrier traymay abut against the upper surfaceof the insulation component. The energy induction traymay abut against the lower surfaceof the insulation component. The insulation componentis made of rubber or plastic, for example. In an embodiment, the insulation componentis, for example, Mylar.

As illustrated in, the sealing component may be disposed between the first coverand the second coverto seal space between the first coverand the second cover, and it may prevent external impurities from invading the space between the first coverand the second cover. The second coverhas a groove, and the sealing componentmay be disposed in the grooveof the second cover. The first coverincludes an abutting portion. When the first coverand the second coverare combined, the abutting portionabuts against the sealing component. The sealis, for example, rubber.

As illustrated in, the pressing platemay be disposed on the second cover. For example, the pressing platemay be disposed on the abutting portionof the second cover. The pressing plateis made of metal, such as aluminum or its alloy. The pressing platehas at least one first through holeand at least one second through hole. The aforementioned first fixing componentA may pass through the first through holeand the through holeof the abutting postof the second cover, and be fixed to the fixing holeof the first coverto fix a relative position among the first cover, the second coverand the pressing plate. The second fixing componentB may pass through the second through holeof the pressing plateand be fixed on the carrierto fix the relative position between the pressing plateand the carrier. In the present embodiment, the second fixing componentB is, for example, an expansion screw. The third fixing componentC may pass through the through holeof the coil carrier trayand be fixed to the fixing holeof the second coverto fix the relative position between the coil carrier trayand the second cover. In an embodiment, the third fixing componentC is, for example, a threaded component, and the fixing holeof the second coveris, for example, a threaded hole.

As illustrated in, the first circuit boardA and the second circuit boardB may be disposed on or fixed on the second cover. The aforementioned charging coiland the foreign object detection coilmay be electrically connected to the first circuit boardA and/or the second circuit boardB to be controlled by the first circuit boardA and/or the second circuit boardB. It should be noted that in the present embodiment, the foreign object detection takes a foreign object made of metal as an example. Therefore, the foreign object detection componentis a metal foreign object detection component, and the foreign object detection coilis a metal foreign object detection coil.

Referring to Table 1 below, Table 1 lists the dynamic simulation stress results of each second fixing componentB when the electric vehicle rolls over the wireless charging devicealong a X direction, and Table 2 lists the dynamic simulation stress results of each second fixing componentB when the electric vehicle rolls over the wireless charging devicealong a Y direction. The electric vehicle rolls over the wireless charging devicewith the parameters in Table 3 (simulated by rolling with single wheel). The numbering of the second fixing componentB is illustrated in. The size of the second fixing componentB is simulated as M8 (metric) and the strength level is 4.8. Its theoretical bearable maximum axial force is 10.5 kN (kilonewtons), and its theoretical bearable maximum shear force is 5.86 kN.

Referring to,illustrates a schematic diagram of a relationship between the safety factors of Table 1 and a plurality of the second fixing componentsB, andillustrates a schematic diagram of the safety factors of Table 2 and a plurality of the second fixing componentsB. The axis of abscissa in the figure represents the safety factor of the second fixing componentB bearing the axial force, and the axis of ordinate represents the safety factor of the second fixing componentB bearing the shear force. It may be seen fromthat the safety factors of all the second fixing componentsBtoB(shown as hollow circles in the figure) bearing the axial force and the safety factors of all the second fixing componentsBtoBbearing the shear force are less than 1 (the further away from 1, the safer the second fixing componentB is). It may be seen fromthat the safety factors of all the second fixing componentsBtoB(shown as filled circles in the figure) bearing the axial force and the safety factors of all the second fixing componentsBtoBbearing the shear force are less than 1. This is sufficient to confirm that the force exerted by the electric vehicle is effectively and dispersedly transmitted to at least one component of the wireless charging devicefor avoiding an excessive concentration of the force exerted by the electric vehicle on a certain component (for example, the second fixing memberB).

According to the static simulation results, no matter which position of the first coverof the wireless charging deviceinis applied statically (along Z direction) by a single wheel weight (applying force), the maximum stresses is borne by the wireless charging deviceare all less than the maximum bearable stress of the first cover. If the material of the first coveris polypropylene (PC), its maximum bearable stress is approximately 62 MPa. The maximum stress statically exerted (along the Z direction) on any position of the first coverof the wireless charging deviceinby the single wheel weight in Table 3 does not exceed 20 MPa, and this is sufficient to confirm that the force exerted by the electric vehicle is effectively and dispersedly transmitted to at least one component of the wireless charging devicefor avoiding an excessive concentration of the force exerted by the electric vehicle on a certain component (for example, the second fixing memberB).

In summary, the embodiment of the present invention provides a wireless charging device. The wireless charging device includes a first cover, a second cover, a coil carrier tray and an energy induction tray. When a force acts on the first cover, the force may be transferred to the second cover through the first cover and the coil carrier tray, and/or transferred to the second cover through the first cover, the coil carrier tray and the energy induction tray. The wireless charging device further includes a component (for example, a coil, a foreign object detection component and/or an energy induction component, etc.), and such component may be disposed between two of the first cover, the second cover, the coil carrier tray and the energy induction tray, and is not subject to a force (not abutted or not clamped) by the first cover, the second cover, the coil carrier tray and/or the energy induction tray. When a force is applied to the first cover, the force is not transferred to such component. In addition, the two abutting components may be in line abutment or surface abutment. Compared with the point-contact, the line-contact or the surface-contact may reduce the pressure exerted on the line or the surface, thereby reducing the stress on the force-bearing component.

While the invention has been described by way of example and in terms of the preferred embodiment(s), it is to be understood that the invention is not limited thereto. Based on the technical features embodiments of the present invention, a person ordinarily skilled in the art will be able to make various modifications and similar arrangements and procedures without breaching the spirit and scope of protection of the invention. Therefore, the scope of protection of the present invention should be accorded with what is defined in the appended claims.